Per our M.O. it's been a little while since we last posted (seriously?! February 17th?). Both a lot and a little has happened in that time. Our snow has melted (all of it!) and we've had some really nice days. Of course, right now it's cloudy, mid 40s, breezy, and about to rain for the next day so we're taking advantage of the "nice" weather and grilling some chicken. Rachel has received word on her schedule of clerkships for next year. We've celebrated Easter and Logan's birthday. I'm working, again. Rachel planted seeds for our garden that will be at our new apartment/house. I drove ten hours to get some leather seats for my car, and I've also done a few other improvements. Like installing a "new" instrument cluster (which you'll learn all about, right here).
Right. So a long time ago I was perusing my TDI forum and came across a posting on how to install an FIS cluster in my car. I read it, of course, and decided that it was something that I would never do. It really didn't seem like anything special. Sure, it replaced the center part of my cluster with an LCD screen that showed miles til empty, fuel mpg, average speed, trip distance and time, outside air temp, and radio station. Big deal. It also had silver faces and different needles. Oooooo.
Fast forward a few years and insert a bored, winter-bound me in my previous place. I've sort of been bitten by the OEM+ bug. That is, I am driven to upgrade my car with factory options (like VW or Audi). For instance, I installed a "comfort clicker" which enables the blinker to blink three times from a single press. Sure, it seems ... lame .. bit it's awesome. And it wasn't a standard (or optional) feature on our cars (in the US). So I added it. Back to the cluster (which was a European TDI option, but not available in the US, of course): it was the beginning of March and I was sick of winter and I needed a project. Queue project.
I had finally worked up the courage to undertake this project (perhaps removing my engine and transmission last year had something to do with this new courage?). There were a few ways to go about it. The easiest way to do this would have been to buy a European FIS cluster and program it (teach it to recognize my keys, essentially) for my car. This would run me about $400 for the cluster. If it was reset to a new condition, I could do the key programming myself, with the car computer program I already have. Option two would be to find a cluster from a Passat W8 (that would be an eight cylinder Passat, of which there were only a few thousand sold in the US) and take the circuit board out of it and then install it into a Jetta housing. This would also require me to solder on an LED and an resistor for the glow plug light, to change out the foils (gauge faces) for ones from a TDI (different red-line on the tach and max speed on the speedometer), and to reprogram it completely so the computer could account for these new scales (3k rpm isn't in the same place on a tach scaled to 5.6k rpm and 8k rpm).
After I decided that it was something I could, and wanted to, do I had to find a cluster. I lucked out and scored one on Craigsslist for $80! The seller was willing to ship it for that price and so a few days later I had my victim. She said it wasn't a problem and was happy to help out a fellow Passat owner! (exclamation point included). I didn't have the heart to tell her I was going to rip it apart and put it in a Jetta.
Anyway. I also managed to get a similar deal on an entire cluster from a 2004 Jetta Wagon TDI. This was great news, too, because the '04 TDIs came with the silver sport faces (which, IMO, look better than the black OEM faces). After lots and lots of reading, I started my project.
Just kidding. One new thing I came across while reading my forums was this thing called inverting an LCD display. Initially, I read it and thought it was stupid and pointless. And then I changed my mind. In a nutshell it's explained in this picture:
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The clock on the left is inverted when compared to the odometer on the right. The individual digits are lit up on the inverted display, where on the standard display the numbers are back-lit. |
Got it? Well, as you can see I changed my mind and added a new project to my project. Inverting displays is a project in and of itself because in order to do it you need two of each display. First, take one clock LCD. The top layer of film on the screen is polarized. And glued, very securely, to the LCD. The object here is to separate the film from the glass WITHOUT scratching the film. I achieved this (after two tries) by soaking it in rubbing alcohol and using a razor blade to split them. Then it's necessary to clean all the glue off the film (still without scratching the film). Once that's finished, take your second LCD screen and peel off the back layer of films. This will leave you with the LCD screen with the top polarizing layer and the piece of glass. Once all the glue is cleaned off the back of the glass you need to orient the films so they cancel each other out. Anyone who's taken a physics class knows what I mean. If you haven't, or can't remember, polarizing film works by allowing light to come through in only one orientation. If you take two films and hold them ninety degrees to each other, no light will pass though. This is what we want (for this). So. Orient them properly, trim them to fit (the front is larger than the back and the LCD has contacts on the rear so you have to trim it in order to get the electrical connection to function), and then glue them together. Without any air bubbles. If you wish to read more (and see some progress pictures),
go here.
So that took a while. I also learned that Passat clocks and odometers were different that those from a Jetta or Golf so that was exciting. When I actually did the inversion I only had two chances to get it right. Thankfully I got it on the first try both times (clock and odometer).
In the meantime I had lots of electrical/computer things to do. One of these was to change some LEDs on the cluster. The center screen on the FIS is red. As you can see in the above picture, the OEM color for the displays is blue. I decided that blue and red wouldn't float my boat and the LEDs behind the displays were easier to change. So, I did some soldering. These aren't the actual display LEDs, but they'll give you an idea of what 3.2mm x 2.8mm looks like:
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LEDs are the little white rectangles. The one in the center is for the glow plug light I soldered that one. The little black things are resistors. I soldered one of those, too. There's way smaller, like two grains of short rice, and way harder to solder. |
You'll notice there's also a corner that's "clipped" on the LED. That denotes polarity. In other words, if it's soldered in backwards, it won't work. I had decided to change the turn signal LEDs from green to blue (the gauge backlights are blue) and had unsoldered the original LEDs without making note of their orientation Doh! I managed to get them right by going to a junkyard and pulling apart a Passat cluster to check...
Long story longer.... I figured out how to make my currently owned car computer software talk to my new instrument cluster. Normally, this would require a different cable AND software (non-pirated versions selling for around $400). I managed to find a guy in the UK who got his cable to talk by downloading some free drivers, and then I got real software for free (completely legally!). That Sunday morning I felt like a genius and couldn't stop smiling (it's true - ask Rachel).
With that hurdle down, I now had the task of actually programming the cluster. This meant I had to learn how to read hex. I won't bore you with those details here (I'm sure you're bored enough already), but let me just say that it looks like alien garble. Here's a screenshot:
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Looks like fun, right? Right?! |
Anywho. I added more to this project by including some European and "hidden" mods, too, like making my temperature gauge show the ACTUAL coolant temp, rather than showing it at operating temp for any temperature from 170* to 210*, and by changing the cruise control light on the dash to make it only light up when cruise is ACTUALLY being used, not just when the switch is turned on and the speed isn't set. Additionally, I enabled lit needles and displays, meaning the LEDs behind the clock, odometer, and needles would light up whenever the ignition is on. And there's a Welcome message that displays when I turn the car on (and am buckled up - which is all the time).
So, with all that taken care of and my new displays on, and my new needles (from an MKV - a Jetta the next body style up), and my new LEDs, and my new foils, I then got to load the new software and run output tests to make sure the needles lined up where the computer said they should (tach at 3k rpm, fuel and temp in the middle, and speedometer at 100 kph). Once that passed it was time to install it into the car. And run some additional wiring. I'd bore you about that, too, but my fingers are getting tired and this is already way too long for most of your attention spans. Or rather, interest spans. On to the pics of the installation:
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Nearly ready to install into the housing. The 180mph scale is from the Passat. You'll notice the red display backlighting and the MKV silver-lined needles. |
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In the housing! And with the TDI sport foils, as the scale is only to 160mph now. |
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That's a roll of masking tape hanging off the steering column. It was not used to hold anything together permanently. |
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This used to scare me. |
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I also changed my air filter while installing the outside air temp sensor. |
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See? Welcome! |
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Last night I started working on a different cluster and am changing the backlights to white. I'll see if I like it... |
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This one only has a half screen computer display. And, for some reason, the trip and odometer displays are flipped.... I have no idea why. I changed the turn indicators (and high beam light) to red on this one. |
So that was how I kept myself entertained during the end of this winter.
Rachel made me a fantastic birthday meal, too! She seared some lamb in butter, rosemary, and garlic, and then finished it off by roasting it in the oven (+1 for cast iron). This was served with a micro-greens salad and some white wine. Chocolate cake was for dessert.
You may also (barely) recall that I mentioned we were moving into a new apartment. This is true, we are. We found a house over by the hospital that fits our needs perfectly. We'll be able to keep Denali with us, there's a garage, it's close to work, the hospital, and the Co-Op, and the rent is reasonable. There's even counter space!! We'll be sharing it with another roommate, who is doing her residency at the hospital. It is also located near a recreation area, so there are trails to ski, run, and bike. And a pond for Denali to swim in. Overall, we're pretty stoked about it and are excited to move in.
If you've made it this far, congratulations. Until the next installment.....